european green cars initiative projects helios proposal paper (july 2012)

F DELCORSO – RENAULT SAS 3d European Green Cars Initiative ProjectsClustering Event – 12th July 2012

PROPRIETE RENAULT

High Energy Lithium-Ion Storage Solutions

Frédérique DEL CORSO

Project coordinator - RENAULT SAS

ac

PROPRIETE RENAULTF DELCORSO – RENAULT SAS 3d European Green Cars Initiative ProjectsClustering Event – 12th July 2012

Project presentation

Project full title: High Energy Lithium-Ion Storage SolutionsCoordinator: Frédérique DELCORSO (Renault)

Partners:

Starting Date: Nov 2009Ending Date: oct 2012 � amendment to oct 2013

Budget Total/Funding: 4,17 MEUR / 2,77 MEURHome page : http://www.helios-eu.org/


UU

RWTH-ISEA & IME2 Universities

ENEA

CEA

INERIS

CNRS - LRCS

ZSWAIT

6Research Institutes

JCHaR

Umicore

SAFT

EDF

4 Industries

PCA

Renault

Volvo

Ford

Adam Opel AG

CRF

6 OEM

HELIOS consortium : 18 partners from 6 member states


Motivation

� Understand the causes of ageing mechanisms (cycling and post-mortem analysis) among 4 chemistries :

� NCA (LiNiCoAl)/ C-Graphite (SAFT –reference)

� LFP (LiFePO4) / C-Graphite

� LMO blend (LiMn2O4-NCA) / C-Graphite

� NMC (LiNiMnCo) / C-Graphite

for EV (electric vehicle),

HEV (Hybrid EV) &

PHEV (Plug-in EV) applications .

NCA : Lithium Nickel Cobalt AluminiumNMC : Lithium Nickel Manganese Cobalt LMO : Lithium Manganese spinel LFP : Lithium Iron Phosphate


Objectives

� Evaluate the performances of 4 positive electrode ( NCA, LMO blend, LFP & NMC/ Graphite anode)

� Manufacturing 280 large cell formats (~40 Ah) – 70 per technology

� Propose safety & life test procedures for High Energy battery cells used in European context

� Comparative assessment of Performance (12- 15 monthscycling tests) life, cost, recycling and safety characteristics


WORK PACKAGE structure

WP5 : Electrical Characterisation of

HE cells (cycling, calendar) (EDF)

WP

8 :

Re

cycl

ing

Fe

asi

bil

ity

Stu

dy

(RW

TH

-IM

E)

WP

7 :

Eco

no

mic

al

Ass

ess

me

nt

(PS

A)

WP 6 : Safety tests

(INERIS)

WP1 : Management / Coordination (RENAULT)WP1 : Management / Coordination (RENAULT)

WP 2 : Ageing

review,

charactrerisation

and interpretation

of results (LRCS)

WP 3 : Specifications and

testing procedures

(OPEL)

WP 4 : Manufacturing of

High Energy Cell

(SAFT)

START


Main results : WP2 (Ageing analysis, post mortem analysis)

� 2.1Bibliographic review on ageing mechanisms� Graphites

� Positive Electrodes

� Electrolyte ageing

� interfaces, characterization techniques

� 2.2 Post-mortem analysis : initial , intermediate (6 mo nths) & final characterization of electrode materials (SEM, Electrochemical measurement, XRD, DSC, Mass spectrometry, XPS )


Main results : WP3 (Cell specification and test procedures )

� 3.1 - Target specification for a High Energy cell sui ted for EV, PHEV and/or HEV-APU applications

� 3.2 - Performance, ageing and cycling test procedure �� inputs for WP5

� 3.3 -safety test procedures (mechanical, electrical and thermal abuseconditions) �� inputs for WP6

� 3.4 : coordination with ISO, VDA & USABC.

�� activities achieved end of october 2012


Main results : WP4 (High energy cell manufacture )

� 4.1 : Material selection for NMC, LFP, LMO

� 4.2 : Build of small sample cells (4/5 A), 12 cells per technology

� 4.3: up-scale study

� 4.4 : Manufacture and delivery of large cells (~40 Ah) to test institutes : 70 cells per technology

Delivery delayed : 10-12 months

All the activities have been performed � WP4 « closed »


Main results : WP5 (Electrical performance testing)

� Cycling tests (15 months):� EV type profile : SOC 100% - 20% Imax ~1.25C (50A) @30 – 45°C

� PHEV type profile : SOC 95-25% Imax ~ 5C (200A) @ 30- 45°C

� Calendar tests (12-15 months) : storage at 45 – 60°C , 100%SOC

� Different Characterisation tests :� Complete Characterisation every 6 months,� Quick Characterisation : every 6 weeks

� Already 6- 14 months of tests performed

Helios Resumé EV Cycling Profile B 30°C 80%DOD

60

65

70

75

80

85

90

95

100

0 100 200 300 400 500 600 700 800 900 1000 1100 1200100% Cycles nom

(accumulated discharge capacity of 80%DOD cycles di vided by nominal capacity)

SO

Hac

t in

%

NCA 12 NCA 09 NCA 05 NCA 01 LMO 03 LMO 04 LMO 05 LMO 08

NMC 11 NMC 06 NMC 03 NMC 09 LFP 07 LFP 09 LFP 08 LFP 10

LMO

NMC

LFP

NCA cycle week 44

LFP


Main results : WP6 (Safety and abuse testing )

� 6.1 bibliographical study of thermal ‘runaway’ mech anisms in lithium battery systems,

� 6.2 : Definition of safety test recommendations, ba sed on WP3 specifications

� 6.3 Thermal stability tests on 0.5 Ah cells� 6.4 : Safety tests on 40 Ah cells (running)

o Controlled crush (Radial and axial )o Penetration (nail)o Thermal stability (ARC)o Simulated Fuel Fire (Beginning of Life)o Elevated temperature Storage (2 months) @ SoC = 20, 50%o Rapid charge / dischargeo Thermal Shock Cycling (from -40 °°°°C / + 75 °°°° C)o Overchargeo Short circuito Over discharge

Crush test(radial)


Main results : WP7 (Economical assessment)

� 7.1 : Cost assessment for Active materials

� 7.2 : Cost assessment for cells

� 7.3 : extrapolation to the pack level cost

According 3 levels of annual manufacturing volumes :- Low quantity : cells quantity equivalent to 50 000 veh / year (41 Ah),

- Mid quantity : cells quantity equivalent to 100 000 / year (41 Ah),

- High quantity : cells quantity equivalent to 200 000 / year (41 Ah).

�� activities achieved end of october 2012


Main results : WP8 (Recycling assessment )

� 8.1 : Study of the potentially most appropriate pro cesses, involving a range of techniques from the least costly but yie lding the lowest quantity of recycled material up to the most expens ive process (cell de-activation + mechanical separation+ agglomeratio n before pyro-metallurgical or hydro-metallurgical treatment), yi elding the most usable material.

� 8.2 at cell level

� 8.3 extrapolation to pack level+ Life Cycle Analysi s

� �� activities achieved end of october 2012.


Milestone plan

* Delay of 9 -12 months to deliver cells according the technologies (selection of materials longer than expected, delay of raw materials supply from Japan, change of production site for LFP…)* Problem of process for LMO (only 50 cells available) and NMC (2 batches were necessary)

Kick-offDelivery of small cells

(0.5 Ah)

Nov2009

Dec2010

Dec2011

June2011

Oct2012

Cycling,calendar &safety tests

Mid-termreport

Delivery of 4*70 cells (40Ah)

Final assessments

on performance, recyclability, cost, safety &

ageingmechanisms

AMENDMENT

Oct2013

Safetyresults &

post-mortem interm.

intermediate report

meetingMMMM

MMMM MMMM MMMM MMMM MMMMMMMM

MMMM


Overall progress

� M18 mid term report submitted on time (june 2011)

� 18 deliverables submitted, 4 are late (draft versi on), 5 are postponed (due to late delivery of cells)

� Delivery of 70 (40 Ah) cells per technology by SAFT

� Start of cycling and calendar tests (6-14 months alreadyperformed)

� Abuse tests of small & large cells achieved.


Next steps, future activities

� End of cycling tests

� Economical assessment

� Recycling study (at cell, pack level)

� Interpretation of the ageing results (post-mortem analysis)

� Dissemination

� 2nd intermediate report : end october 2013


Exploitation potential

� HELIOS results would influence the choice and the integration of the best technologies on reliable, safe, cost and recyclability points of view, in vehicles (VE, PHEV) or trucks (HEV-APU) that will contribute to reduce the CO2 emissions .

� Specification of Common European procedures (Cycling & safety) for High Energy Li-ion batteries �� inputs in European standards.


Cooperation within the cluster

Testing procedures, Cost assessment

EUROLIION

recycling


Thanks for your attention

� For additional information,http://www.helios-eu.org

[email protected]

+33 1 768 57 598

european green cars initiative projects helios proposal paper (july 2012)

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